Process of and apparatus for forming articles from plastic sheet material



Jan. 21, 1941` c. B. s'rRAucH 2,229,613

PROCESS 0F AND APPARATUS FOR FORMING ARTICLES 'FROM PLASTIC SHEET MATERIAL Filed Nov. 22, 195s 12 Sheets-sheet `1 PROCESS OF AND APPARATUS FOR FORMING ARTICLES FROMAPLASTIC SHEET MATERIAL Jah. 21, 1941. C'. B. STRAUCH 2,229,613

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FOR FORMING ARTICLES FROM PLASTIC SHEET MATERIAL Filed Nov. 22. 1938 l2 Sheets-Sheet '7 Innen UF: @lamas Strauch @y www A orn ya Jan. 21,1941. c. B. sTRAucH PROCESS OF AND APPARATUS FOR FORMING ARTICLES FROM PLASTIC SHEET MATERIAL 0 8 s. A w @o .m W s. .t 4 W U y m im M 6 S L D a w 9 4 QM nt n t 2 5 @qu F e 4 flu 2. y J 0 e 2 l l .4/ wl h 6 .5 lv@ s 7 5 Z F 4 n.5 7 2 3 2 2 2 8 nl @u 5 2 6 7 3 3 3 2 5 2 Z Qu u 2 2 5 2/ a QJ H j n/m Z J Ta H y f y Q Y .n fmwwm Fild Nov. 22, 193s Jan. 21, 1941. C, B, sTRAucH PROCESS 0E AND APPARATUS E oa EORMING ARTICLES Enom PLASTIC SHEET MATERIAL 12 Sheets-Sheet 9 Filed Nov. 22, 1938 l [12 @en tor:

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Jan 21, 1941- c. B. sTRAucH 2,229,613'

PROCESS OF AND APPARATUS FOR FORMING ARTICLES FROM PLASTIC SHEET MATERIAL FROM PLASTIC SHEET MATERIAL Jan. 21, 1941. c. B. s'rRAUcH PROCESS 0F AND APPARATUS FOR FORMIING ARTICLES Filed Nov. 22, 1938 12 Shegts-Sheet l1 458 of f6 Il. bgg

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Jan. 21, 1941.u Y c. B. sTRAucH 2,229,613

PROCESS OF AND APPARATUS FOR FORMING ARTICLES FROM PLASTIC SHEET MATERIAL Filed Nov. 22, 1958 l2 Sheets-Sheet 12 Inventor: W Clauss'trauch ,l 1295s. by *j Z- #m A ttorneys.

` of the sheet, sufficiently to Patented jan. 2i, i941 'narran stares arrasar smear ortica ING ARTICLES FROM TEBIAL' Clauss Burkart Strauch,

assignments, to ilax Corporasignor, by mesne tion, Hartford, Gunn., ware lPLASTlC SHEET MA- Milwaukee, Wis., as-

a corporation of Dela- Applicatlon November 22, 1938, Serial No. 241,722

37 Claims.

This application relates to a process of and apparatus for forming articles from plastic sheet material and more particularly to the forming of articles by die-pressing from relatively thin sheets of organic plastic material to form deeper draws in proportion to the thickness of the material than has `heretofore been found possible or practicable. As such, the invention is a continuation in part of my copending applications, Serial Nos. 56,905 and 143,113, iiled respectively December 31, 1935, and May 13, 1937, both of which applications are to be abandoned in favor of the present one.

Among the objects to provide a process and ing articles from sheet plastic material by heating a selected portion thereof, usually centrally render the material of this portion plactic and moldable, while preventing distortion of the heated portion of the sheet, which might otherwise occur, by holding certain at least of the perimetrically disposed unheated portions of the sheet against relative movement. The heated portion of the sheet is then formed to the shape of the desired article by the application of differential pressure to opposite sides thereof, usually by cooperating' dies, which operation usually occurs at a point spaced from that at which the sheet is heated in order to utilize the necessary apparatus to the maximum extent.

A further object of this invention is to for the carrying on of the heating and forming steps of the process at different places, so that these operations may occur simultaneously or in some overlapping time relation, either on different sheets or on diiferent parts of the same sheet or strip of plastic material.

A further object of the invention, when using dies as above set forth, ls to provide4 for the rigidiiying of the plastic material concomitantly with the shaping thereof by controlling the temperatures of the dies to a point such that this result will be effected. In the case of thermoplastic material, the dies are normally cooled, or in any event maintained at what below the softening point of the material being worked. The temperature of the dies will. of course, depend upon the' characteristics of the plastic material being worked and the speed of operation.

A further object of the invention is to provide for the forming of articles by a process and with apparatus as above set forth by which articles, such as filters, which may be used as nasal inof the present invention are an apparatus for formprovide (CL 18d-19) halers or otherwis tions formed of `plastic material as aforesaid, are then perforated by suitable means and thereafter are filled with a suitable filtering material.

A further object of the invention is to provide for the forming process aforesaid, maintained integral with the parent body or strip of the sheet'from which they are formed until the formation and filling, if such be done, is completed: after which the article is cut or blanked out from the remainder of the sheet or strip.

A further object of the present invention is to carryon some or all of the processes referred to above, using a long strip'of material, such as thermoplastic material, the several operations being performed preferably simultaneously or in .some overlapping time relation on different portions of the strip and along the path of movement thereof.

A further object of the present invention is to provide for the holding of certain portions only of the perimetry of an area from which an article is to be formed, other portions between the held portions being free to move as by the forming of slits along the perimeter to permit the movement of the material in drawing away from the slitted portions during the forming thereof and so as to permit the inclusion of a larger percentage of the material of the original sheet in the completed article. In this connection the slits may -be formed parallel to one another on oppostie sides of the area to be formed, at the corners thereof and extending part way along each side from such corners, or in other selected ways.

Another object of the invention is to provide for the forming of articles by deep drawing as aforesaid, by the use of dies wherein the female die is so arranged as to be closed in order that air be trapped between the female die and the sheet during the l:forming of an article in such die, so that this air. which escapes between the female die and the sheet during the forming of an article, will serve as a partial insulation to prevent too rapid cooling or temperature changes in the sheet, which would tend to rigidify it prior to the completion ofV article. v

A further object of the invention is to provide for the positive cooling of the portions of the sheet which are engaged by holding means to prevent their relative movement, while the central portion of the sheet is heated and/or is still soft, so as to retain the held portions of the and which have shell por.

of articles according to the. wherein the articles formed are.

the formation of the l sheet against softening from their normal rigid Fig. l is a view substantially in vertical seccondltion to provide adequate means for holding tion on the line ld-l of Fig. 5 illustrating the sheet during the heating and forming thereof. the maten'al moving means A further and more specic object of the in- Fig. 11 is a view substantiallyin vertical section 5 vention isfto provide, in e forming of articles on the line ll-ll of Fig. 5 illustrating the per- 5 from an elongate strip o material as aforesaid, forating unit; for bending the lateral edge portions of the strip Fig. 12 is a View substantially in vertical secto form laterally disposed llanges, which may be tion on the line l2l2 of Fig. 6 illustrating the passed through suitable guides for preventing adhesive-applying unit; l0 relative movement of the lateral portions of the Fig. 13 is a view substantiallyiin vertical sec- 10 sheet during the heating of the central portion tion on the line l3`|3 of Fig. 6 illustrating the thereof, the guides themselves preferably being cotton unit; positively cooled. Fig. 14 is a view substantially in vertical sec- A further object of the invention is to provide tion on the e l 4-14 of Fig. 6 illustrating the l5 an apparatus for carrying out the several process cutout unit; 15 steps aforesaid, which will be relatively simple Fig. 15 is a view substantially in vertical secin construction and automatic and free from tion 0n the same plane as that 0f Fig. 6, but on continuous manner. The apparatus hereby prothe adhesive applying unit; 20 vided preferably is vsuch as will require little at- Fig. 16 is a fragmentary view with certain of tention once it has been properly adjusted and the parts shown in vertical section and other Further and more Specic objects' of the n- 13 of the cotton unit, the view being taken from the rear of the machine; l form of apparatus for carrying out the process Fig. 17 is a diagrammatic view substantially steps as hereinabove mentioned, including the in vertical section illustrating the process apsteps for forming iianges on the lateral edges of plied to the production of nasal inhalers; a continuous strip of plastic material, the pro- Fig. 18 is a view similar to Fig. 17 with the vision of means i'or heating the central portions parts in different positions; 30 only of the strip while maintaining the edges Fig. 19 is a plan view illustrating a frame holdcool so that they may be held against relative ingasheet of organic plastic material from which movement during the forming of articles with an article may be formed according to the incooperative dies while concomitantly rigidifyvention; ing the articles during the forming thereof; and, Fig. 20 is a verticalsection of the apparatus of 35 in the specic embodiment of the invention here- Fig, 19 taken on the line 20-20 of that ligure; inV disclosed for making nasal lnhalers. the in- Fig. 2l is a diagrammatic view substantially i n showing the frame and sheet toms of the shaped portions of the strip, means of Figs. 19 and 20 held adjacent to a sourceof 40 fOr Supplying an adhesive t0 the interior 0f the heat for heating a selected portion of the plastic 40 shaped and perforated portions and thereafter sheet;

therein. The invention also includes means: for article; cutting out the formed articles, irrespective of Fig. 23 is a view, similar to Fig. 22, showing their shape and subsequent use from the rethe dies in position in contact with the sheet mainder of the strip. for forming it Other and more detailed objects of the present Fig. 24 is a similar view showing the sheet 50 invention will become apparent from the followformed and the dies separated therefrom; ing speciication and appended claims when taken Fig. 25 ls a similar view showing the article in connection with the accompanying drawings, formed by the process of Figs. 22 to 24 being in which: Figure 1 is a view in elevation showing subcutting means being shown in vertical section; 55 stantially the entire machine for making nasal Fig. 26' is a view substantially in plan illustratinhalers from thermoplastic material and filling ing a rotary type machine by which the process them with cotton; illustrated in Figs. 19 to 25 inclusive may be Fig. 2 is a plan view of the machine of Fig. 1; performed: 50 Fig. 3 is a view substantially in end elevation Fig. 27 is a diagrammatic detail view in vera0 from the left-hand end of Fig. 1; tical section of one of the frames of the type Fig. 4 is a fragmentary view substantially in illustrated in Fig. 26 with a sheet held therein; end elevation from the right-hand end of Fig. v1; Fig. 28 is a view similar to Fig. 27 illustrating view substantially in longitudinal vertical section a heating means; 05

of the machine of the previous gures; Fig. 29 is a similar view showing dies for form Fig. 7 is a view substantially in vertical secing an article from the sheet and the forming tion on the line 1 1 of Fig. 5 illustrating the thereof: langing unit; Fig. 30 is a similar view illustrating the blank- Fig. 8 is a view substantially in vertical secing or cutting out of a finished article from the 70 tion on the line 8 8 o1' Fig. 5 illustrating the sheet while it is still held in the frame; heating unit; Fig. 31 is a view similar to Fig. 27 of the frame Fig. 9 is a view substantially in vertical section and the remainder of the sheet after a finished on the line 9-9 o1' Fig. 5, illustrating the shaparticle has been blanked or cut out therefrom; lng unit: Fig. 32 is a-view in plan showing a sheet having 75 spaced parallel slits therein from which an arti-` cle may be formed by the process illustrated in Figs. 19 to 25:

Fig. 33 is a plan view showing a frame holding the sheet of Fig. 32 after an article has been formed therefrom;

Fig. 34 is a view substantially in vertical section on the line 34-34 of Fig. 33; and

Figs. 35, 36 and 37 are a series of views corresponding respectively to Figs. 32, 33 and 34, wherein the sheet is slit at the corners and extending part way along each side.

While the process of the present invention may be carried out in the making of many diiferent types of articles and in the filling of containers, and including semi-nished articles whichl must be subjected to further manufacturing operations before being in the ilnal desired form, there is chosen for illustration in the present case an apparatus for the making of nasal inhalers from thermoplastic materials, such for example as cellulose acetate. This material as disclosed herein is supplied in strip form from .005" to .015" in thickness and is disclosed as being of such width that two similar articles are formed across the width of the strip or ribbon. It will be understood, however, that the same process and the same or similar apparatus may be used in the production of many other types and shapes of articles, and one or more of such articles may be formed across the width of the strip used, depending upon the size of the strip available and the size or dimensions of the articles to be formed.

A machine built in accordance with the present disclosure, and corresponding to that shown in Figs. 1 to 16 of the drawings of this application, has been built and successfully operated in the making of nasal inhalers at relatively high speeds and in a fully automatic manner.

THE MACHINE OF FIGS 1 to 16 GENERAL CONSTRUCTION The machine shown in these figures comprises a pair of base boxes 1 and 8, the box 1 being used to contain the prime mover for the apparatus here shown as an electric motor 9 while the box 8 is hollow and may be used for storage of any desired equipment for use in conjunction with the apparatus. The boxes 1 and 8 arefprovided respectively with suitable brackets I8 and II connected by a transverse table I2, which may be of wood or any other desired material, the construction thus far described being used solely for providing a mounting and a driving means for the remainder oi' the apparatus.

Mounted on boxes 1 and 8 respectively are a pair of similar leg castings I3 and I4 connected together at their upper ends by longitudinally extending rails I5 and I6 and at their lower ends by a pair of spacer vor tie rods I1 and I8. All the apparatus for performing the several operations is mounted on this frame structure, as hereinafter set forth'.

Inasmuch as all the several units are driven in synchronism and from a common drive, the main drive shaft and the manner of rotation thereof will now be described. This drive shaft is shown in Fig. 2 at I9 and extends longitudinally of the machine at the rear thereof, being journaled in bearings formed in brackets 20, 2| and 22. The main drive shaft I9 may be driven by any suitable source of power, such for example as a prime mover here comprising the electric motor 9. 'Ihe motor 3 is provided with the usual pulley 23, Fig. 1, arranged to drive a belt 24 passing around a larger pulley 25 on an intermediate shaft 2E. which is journaled in suitable bearings formed in the box 1. This shaft 26 also carries a relatively small pulley 21, Figs. 1 and 3, driving a belt 28, which passes around a pulley 28 secured to the drive shaft I3. An intermediate idler 38 is provided on a stub shaft 3l, which is adjustable along a slot 32 so as to effect a desired tightening of the belt 28. There is thus provided a direct drive from the motor 8 to the drive shaft I9 with a speed reduction interposed therein.

In the machine shown, the plastic material from which articles are formed is supplied in the form of a long strip or ribbon which is received asa roll 33, Fig. 1. This roll is preferably wound on a suitable hub 34, Fig. 2, having a spindle 35 concentrically thereof, the ends of which are recessed to receive a rear pin 36 extending from a bracket 31 secured to the rail I6 and a forward pin 38 which is spring-pressed inwardly into engagement with the spindle 35 and is mounted in a bracket 39 secured to the rail I5. The arrangement is such that when a roll 33 is to be changed, a handle 48 secured to the pin 38 may be withdrawn, compressing the spring surrounding this pin and permitting the roll to be changed as will be obvious from the foregoing description. Any other means for supplying plastic material to the apparatus in the form of an elongate strip or ribbon could be used in place of that herein shown and described as desired. l

In the machine shown, the ribbon passes along a predetermined path, along which are arranged a plurality of units, each of which performs a certain operation on the ribbon in the forming of articles therefrom. These units comprise a ilanging unit 4I, a heating unit 42, a forming or shaping unit 43, a material driving or moving means including a pair of driving rolls and associated mechanism 44, and a plurality of pusher finger units associated with other units as hereinafter described, these pusher ngerunits being indicated at 45, 46 and 41. There are also provided along the path of the ribbon of plastic material a perforating unit 48, an adhesive applying unit 49, a cotton unit 50,` and a cutout unit 5I. These units will be described in separate sections hereinafter.

Flanging unit 41, Figs. 1, 2, 5 and 7 The plastic material to be used as a basis for forming the articles is drawn off the roll 33 in a strip 52 by means hereinafter to be described and is first passed through the anging unit 4I. In this unit the lateral edge portions of the strip 52 are bent atangles to the plane of the main body of the strip, in this case into substantially vertical planes and downwardly about longitudinally extending parallel fold lines. This is effected between a pair of rolls as hereinafter specically set forth, one of these rolls having end flanges extending over the ends of the other of the rolls.

As shown in the accompanying drawings, the unit 4I is mounted upon a supporting frame 53 from the rails I5 and I6. The frame 53 has angularly disposed portions engaging the insides of these rails and the undersides thereof. To these portions are secured top cover plates 54 by bolts 55. Threaded through the plates 54 are set screws 56 adapted to bear upon the upper surfaces of the rails I5 and I8. In this Way the entire'unit 4I, all of which is carried byI the frame 53, may be adjusted longitudinally of the machine and secured in adjusted position by the set screws 56. Suitable stops 51, Fig. 2, are provided for determining the endmost limit of the adjustment as aforesaid toward the heating unit 42.

The principal body portion of the flanging unit comprises a pair of side frame members 58 which are secured to the frame 53 as by bolts 59, there being a suitable plate 60 of heat insulating material between the frame members 58 and the frame 53. The frame members 58 are connected at their tops by a member 6I which serves as a lower entrance guide for the strip 52. Above the lateral edges of the member 6I are guide 'strips 62 between which is formed the entrance guideway for the strip 52 of plastic material. The members 62 and 6I are secured to the frame members 58 by suitable bolts 63 as shown. Resting upon the plastic material strip as it passes over the member 6I and between the members 62 is a cover member 64 which has adjacent to its right hand end, as seen in Fig. 5, an upturned flange portion 65, the lateral ends of which abut against upstanding portions of the frame members 58 as seen in Fig. '7.

On entering the ilanging unit 4I the strip 52 of plastic material passes overa flanged idler roll 66, Fig. 5, so as accurately to guide it into the space between the members 6I and 64, the shaft of the roll 66 being suitably 'journaled in the frame members 58.

The eiiective shaping of the strip in the unit 4I is accomplished by cooperating rolls including a cylindrical lower roll S'I and a flanged upper roll 68, the latter having end flanges 89 extending over the ends of the roll 6l. The lower roll 61 is mounted on a shaft 'Iii journaled in suitable bearings in the frame members 58, while the upper roll 68 has its shaft mounted in rectangular bearing blocks 1I, Fig. 1, which are arranged for vertical movement between pairs of parallel guide portions integral or rigid with the frame members 58. The upper ends of these guide portions are connected together at each side of the device by bridging members l2. Extending upwardly from and secured to the bridging member 'l2 on each side is a pin 13, the upper end of which is threaded and provided with a vertically adjustable stop collar M. Vertically f slidably mounted on each pin I3 is a collar 'I5 which is urged downwardly on the pin I3 by a compression spring 16. 'Each collar i5 rests upon a pair of pins l1, Fig. 5, extending upwardly from and secured toone of the bearing blocks 1I and passing freely through holes Ain the associated bridging member l2. The arrangement is such, therefore, that the compression of the springs 76 urge the bearing blocks 'II downwardly in their guides, the compression of the springs I6 being adjustable by threading the collars I4 up or down on the pins '13.

At their right hand ends, as seen in Fig. 5, the frame members 58 are connected together by upper and lower exit guide members 'i8 and 19, which are secured to the frame members by bolts 80 and are spaced apart a suitable distance to accommodate the strip 52 with the Adownturned flanges thereof. LThe frame members 58 are also connected together'and spaced apart by a spacing rod 8l, the ends of v'whichiare reduced in diameter to pass throughsmall diameter holes in the frame members 58 and are provided with suitable nuts 82 at their outer ends.

The rolls 61 and 68 are geared together at their rear ends by gears 83 and 84 which are secured to the shafts of these rolls so that they vwill turn in unison. They are not, however, driven except by the passage of the ribbon 52 of plastic material therebetween.

Suitable means, here shown as a heating element 85, Fig. 5, may be provided for supplying sufcient heat to the material of the strip 52 so that the edge portions thereof may be permanently bent downwardly to form anges as hereinabove explained. This element is formed as a metallic block 86, Fig. 7, provided with a pair of bores 81 in which may be located electric heating elements of the resistance type. Suitable wires 88, Fig. 5, may lead to the electric elements in the bores 81 from a source of electric power. The current supplied to the heating elements is preferably controlled in a desired manner, as by a rheostat (not shown), in order that the heat supplied to the material may be regulated in accordance with the characteristics of the plastic material being used. It is preferable thatthe material be heated just suiiiciently so that the edge portions thereof may be permanently bent into flanges, as above set forth, without heating it to such an extent that any distortion could occur in the main body of the material itself under the influence of the heat.

Heating unit 42, Figs. 1, 2, 5 and 8 The next step performed on the material of the strip 52 is to heat the central body portion thereof suciently so that the material thereof becomes plastic and moldable. If this were done to the extent to which it is done according to the present invention, Without adequate support for the heated portion of the strip, it would be impossible to prevent such distortion of the material of the strip as would render the further operations impossible. It is necessary therefore, especially when working with relatively thin material, to support certain at least of the portions of the strip arranged about the heated portion against relative movement, so that the central portion which is heated and which is not self-sustaining at the temperature to which it is heated, will be prevented from distorting to such a degree that further operations cannot be effected. This is accomplished according to the present invention by maintaining the strip under a suihcient longitudinal tension coupled with maintaining the lateral edge portions of the strip relatively cool and hence rigid, and preventing these rigid edge portions from relative movement. To this end means are provided for guiding the flanged edge portions of the strip formed as aforesaid in unit 4I through positively cooled guides.

Turning now to the drawings, particularly Figs. 5, 8 and 9, a pair of frame members 89 and 99 are provided extending between the rails I5 and i6 and suitably secured thereto by bolts 9|, Fig. 8, or in any other desired manner. vThe lateral edge portions of the strip 52 is'supported by `lower guide members 92 and 93 above which are upper guide members 94 and 95. vThe guide members 92 and 93 have vertical longitudinally extending slots 96 formed thereinto accommodate the downtumed anges of the strip 52; while the upper guide members 94 and 96 'have their under surfacesrecessedsufficiently to accommodate the thickness of the horizontal plane portion of the plastic material strip. All the guide members 92 to 95 are provided with hollow temperature controlling chambers 91 to and from which a temperature controlling :fluid may be passed through suitable pipes 98. When using thermoplastic material for which the machine now being described was specifically intended, the f chambers 91 will be provided with a cooling fluid to maintain the edge portions of the strip cool and hence rigid, so as to prevent undesired attenuation of the strip under the inuence of the longitudinal tension exerted thereon while the central portion thereof is heated and while the parallel slots 96 prevent relative lateral movement of the edge portions of the strip.

Means are provided for suspending the guides 92 to 95 from the transverse frame members 89 and 90 in such a way as to accommodate strips of various widths. For this purpose, the guides 92 and 94 on the one hand and 93 and 95 on the other are suspended from the frame members 89 and 90 at each end by specially shaped bolts 99, Fig. 5. These bolts have reduced lower end portions passing through the lower guide Y members while larger diameter portions pass through apertures in the upper guide members, there being a shoulder between these two portions abutting the upper sides of the lower guide members, as best seen in Fig. 5. The bolts 99 are suitably secured to the lower guide members by nuts at the lower ends thereof. These bolts each have a flange |0| for engaging against the underside of the transverse frame members 89 and 90 and have non-circular portions extending upwardly through slots |02, Fig. 2, in these frame members. The bolts 99 are secured to the frame members 89 and 90 by nuts |03 threaded on their upper ends and tightened against the frame members. Thus the lower guide members 92 and 93 are rigidly secured to the transverse frame members `80 and 90 at their ends so as to predetermine the underside of the path of the strip 52 of plastic material, while permitting lateral adjustment of the guides 92 and 93 by loosening the nuts |03 and moving the bolts 99 laterally in the slots |02. The upper guide members 94 and 95 are provided surrounding the bolts 99 adjacent to the lower portion of the apertures through which these bolts extend with inwardly extending flanges, between which and the flanges |0| on the bolts 99 are arranged compression springs |04. Thus, the upper guide members 94 and 95 will be adjustable laterally simultaneously with the respectively associated lower guide members 92 and 93, while the upper guide members will be resiliently urged downwardly into contact with the upper surface of the strip 52 of plastic material at the lateral edges thereof by. the compression of the springs |04.

While it is possible to heat plastic material which is relativelyy thin to an adequate extent by heat supplied thereto from but one side, it is preferred to supply heat to the material from both sides thereof, in this case from above and below, by means which supply the heat primarily by radiation. Such means in the present instance comprise metallic blocks including a lower block |05, Figs. and 8, which is provided with suitable bores as indicated at |06 in which heating units preferably of the electric resistance type may be provided. such units being supplied with current through wires |01 froma suitable source of power, there being preferably interposed in the line suitable current controlling means, such as a rheostat (not shown).

'I'he block |05 is provided on its underside with a heat insulating panel |08 which is apertured to permit the attachment to the block` |05 of a bracket |09 formed in the shape shown in Fig. 5. The bracket |09 is secured to an L-shaped bracket H0, the vertical leg of which is provided with a slot through which passes a screw ||2 threaded into a stationary bracket H3. The bracket H3 has a laterally extending portion secured to the leg I3 of the machine by a bolt ||4 and is provided with a guide channel in which the vertical slotted portion of the bracket ||0 is slidable. By this construction the heating block |05 may be vertically adjusted and the adjustment secured by tightening the screw ||2.

Arranged above the path of the strip 52 of material is an upper heating block ||5, which is somewhat shorter in longitudinal extent than the block |05, but is otherwise constructed in a similar manner and is similarly provided with a plurality of electric heating elements I|6 supplied with current from wires |l1 from a suitable source of power and under control of suitable means ,as a rheostat (not shown). The controls for the temperatures of the upper and lower blocks ||5 and |05 are preferably independent of each other. The block ||5 may be surrounded by a casing ||8 of heat insulating material it desired.

The block ||5 is carried by a transversely extending arm ||9 and is suitably vertically adjustable in respect thereto in a manner hereinafter to be described. The arm ||9 is pivoted at |20 to a bracket |2|, which is in turn secured to the rail I6 of the machine. At its forward end, the arm H9 has a. handle |22 which may be manually grasped to lift the arm ||9 and swing it about the pivot |20 to raise the upper heating block Il'e out of heat-transferring relation with the strip of plastic material by movement from the full line to the dotted line positions, Fig. 8. This is normally done when for some reason movement lof the strip 52 is stopped for any substantial period, in order to prevent overheating of the strip and damage to the material thereof. Suitable stops are provided on the arm ||9 and the bracket |2| respectively for predeterminlng the terminal positions of the arm on the manual swinging movement above described, including a stop |23 on the arm I9 adapted to engage a xed ange or web |24 of the bracket |2| to predetermine the dotted line position of the arm and associated parts, Fig. 8, and an abutment |25 on the arm ||9 arranged to engage the upper end of an adjustable stop v|26 secured to an inwardly extending portion of the bracket |2|. The operative position of the arm ||9 can thus be adjustably determined by the adjustment of the stop |26.

The block ||5 is provided with a pair of bolts |21 secured therein and extending upwardly therefrom loosely through suitable bores in the arm I I9 and through sleeves |28 and a plate |29 resting upon or secured to the sleeves |28. Above the plate |29 are a pair of nuts |30 threaded on the bolts |21 and provided with small pinions |3|, both of which mesh with a gear |32 journaled about a stub shaft which is mountedI in the plate |29. Secured to the gear v|32 for rotation about this stub shaft is a hand wheel |33.l

Thus, rotation of the hand wheel |33 will rotate the gear |32 and simultaneously rotate the nuts to adjust the block I5 vertically in respect to the arm ||9.

Also secured in the plate |29 is a thermometer Forming or shaping unit 43, Figs. 1, 2, 5 and 9 As shown in the accompanying drawings and as carried out in the machine corresponding thereto, the articles are formed from the heated portion of the ribbon 52 by a pair of cooperating dies,

including upper male dies |31 and lower female Cil dies |38. The upper dies |31 are interchangeably secured by bolts |39 to a temperature controlling chamber I40, which in turn is secured to the lower head of a slide |4|. The slide I4| is mounted in suitable guides |42 formed in a large transversely extending bracket |43, which is secured as by bolts |44 to the rails I5 and I6. The lower die |38 is also interchangeably secured through spacing blocks |45 to the upper head of a slide |46 arranged for movement in guideways |41 aligned with the guideways |42 and in the lower portion of the bracket |43.

Means are provided for moving the slides |4| and I 46 to bring the dies substantially simultaneously into cooperative relation with the heated central portion of the strip 52. For this purpose, the slides |4| and |46 are respectively provided with cam rolls |48 and I 49 which respectively engage the peripheries of upper and lower cams |50 and |5|. The cams |50 and |15| are suitably mounted on shafts |52 and |53 respectively which extend parallel to each other and longitudinally of the entire machine and are journaled in suitable bearings in the frame |43. At their ends opposite from the cams |50 and |5| the shafts |52 and |53 have secured thereto similar sprocket wheels |54 and |55. About these sprocket wheels there is passed a sprocket chain |56 which passes around and is driven by a sprocket wheel |51 mounted loosely on the drive shaft I9 and arranged to be driven thereby through a suitable slide clutch. This clutch includes a member |58, Fig. 2, secured to the sprocket wheel |51, and a complementary clutch member I 59 splined on the shaft 9. These clutch members have but a single position of engagement with one another, so that when the sprocket |51 is driven, it will always be in synchronized timed relation with the rotation of the shaft I9. The clutch member |59 has an annular groove formed, therein arranged to receive a pair of rollers |60, Fig. 9, mounted on shafts extending inwardly from the bifurcated end portions I6| of a clutch operating lever |62. The lever |62 is pivoted at |63 to a bracket secured to the rail I6 and has at its forward end a handle |64. Depending from the rail l5 is a bracket I 65 surrounding the lever |62 and provided with a pair of detents (not shown) engaging said lever, so that the lever will be held against undesired movement at either of its terminal positions, i. e., with the clutch |58|59 either in or out. The sprocket chain |56 also passes about an intermediate idler sprocket I66 mounted on a. short shaft which is journaled in a bracket |61 secured to the rail I6 as shown in Fig. 9.

Thus, as the sprockets |54, and |51 all have the same number of teeth, the cams |50 and |5| will be rotated a single revolution for each revolution of the shaft I9 and will be maintained in synchronism with the rotation of this shaft, which is similarly synchronized with the other operating means of the machine as hereinafter set forth.

For retaining the cam rollers |48 and |49 in engagement with their associated cams |50 and |5| and for retracting the dies' from engagement with the material when this action is permitted by the position and configuration of the cams, the slides I4| and I 46 have secured thereto tension springs and |69 respectively, the opposite ends of which are secured to brackets |10 and I1| respectively, carried by the frame |43. The effect of this construction is to provide a means for forcing the dies positively into engagement with the plastic material while resiliently withdrawing them therefrom.

It is desired that the material being shaped be rlgidiiied concomitantly with the shaping thereof. For this purpose, the dies are controlled as to temperature. As shown, there is provided a chamber |12 in the member |40 to and from which temperature controlling fluid may be passed by pipes, one of which is shown in Fig. 5 at |13; while the lower dies |38 are similarly provided with a temperature controlling chamber |14 to and from which temperature controlling iiuid may be passed through suitable pipes, one of which is shown at |15.

It will be understood that when the device is operating with thermoplastic material, the dies will normally be kept somewhat cooler than the softening point of the material by circulating a cooling media through the chambers |12 and |14. On the other hand, if thermosetting material is being worked, a heating medium may be passed through these chambers for effecting rigidilcation of the material during and preferably substantially coextensive with the shaping thereof.

Material moving means-Unit 44,

and 10 Figs. 1, 2, 5

the unit 44 is provided with a pair of rolls whichv are positively but intermittently driven to draw the ribbon 52 through the portion of the machine up to this point, the requirement that the ribbon 52 drive the rolls 61 and 68 of the unit 4| serving to maintain the ribbon between the units 4| and 44 under a desired tension. This tension is to a certain extent at least controlled by the tension of the springs 16 urging the rolls 68 and 61 together.

Unit 44 is in many respects similar to unit 4| in that it is mounted on a frame member |16, Fig. 10, which in this case is rigidly mounted on the rails I5 and I6 by bolts |11. Supported upon the frame |16 are a. pair of plate-like frame members |18 and |19, which are bolted to the frame |16 by bolts |00 and are connected together by a plurality of spacing members 8| having reduced end portions passing through the frame members |10 and |19 and provided with nuts |82 threaded on their outer ends. Journaled in the frame members |18 and |19 is a shaft |83 carrying a roll |84 which has la plurality of knurled portions |85 separated by annular channel portions |88 to permit passage of the depressions formed in the ribbon 52. Above the roll |84 is a roll |81, which is of smaller diameter than the roll |84 and is adapted to keep the plastic material in 'contact with the knurled portions |85 of the roll |84, being provided with complementary knurled portions for this purpose. The roll |84 is mounted in fixed bearings as above set forth, while the roll |81 has its bearings formed in vertically slidable blocks |88, Fig. 1, corresponding to the blocks 1| of unit 4|- and urged downwardly by the same type of mechanism, which is generally indicated at |89. The description of this mechanism will not be repeated as it is substantially the same as that previously described for the unit 4|.

While it is contemplated that the material could be driven continuously through the machine if means were provided in connection therewith for forming material during the movement thereof, the present machine is designed for intermittent operation, that is, the material is moved intermittently therethrough, the several means for operating on the sheet or ribbon other than the heating means, cooperating therewith during the dwell periods in the movement thereof. '.lhus the forming means, unit 43, forms shaped depressions in the ribbon while it is stationary, and in the manner previously set forth.

Means are therefore provided for moving the material intermittently through the apparatus, which in the present instance, comprise means for rotating the roll |84 intermittently, the roll |81 not being positively driven.

For this purpose, the shaft |83 of the roll |84 is provided to the left of the frame member |18, Fig. 10, with a ratchet wheel with which cooperates a pawl |9|- pivoted to a swinging arm |92, which is arranged for free rotation about the axis of the shaft |83. Suitable spring means (not shown) are provided for urging the pawl |9| against the ratchet |90 in the usual manner. The arm |92 is connected at a point spaced from the axis of the shaft |83 through a. link |93 with the left-hand end as seen in Fig. 5 of a longitudinally reciprocating bar |94. The bar |94 extends for substantially the remainder of the length of the machine, that is to the right of the unit 44, as seen in Figs. 5 and 6, being mounted for longitudinal reciprocating movement in suitable bearings formed in brackets |95 and |96, which are carried by the rail I8.

For reciprocating the bar |94, this bar has pivoted thereto at |91, Fig. 2, a lever |98, Fig.

. 10, the outer or rear end of which is bifurcated to embrace a bolt |99 securedly mounted in a bracket 200 which extends rearwardly from the rail I6. Mounted for pivotal movement on the bolt |99 is a second lever 20|, the inner end of which is disposed between an upstanding portion 202 of the lever |98, Fig. 2, on the one side and a second upstanding portion 203 of the lever |98 on the other side. Extending between the portion 203 and the adjacent side of the lever 20| is a compression spring 204. Thus, referring to Fig. 2, when the lever` 20| is moved clockwise about its pivot on the bolt |99, the left-hand inner end will engage the upstanding portion 202 of the lever |98 to move the bar |94 to the left with a positive movement. If the lever 20| is moved counterclockwise, it will move the bar |94 from left to right with a resilient movement through the compression of the spring 204 disposed between the inner end of the lever 20| and the adjacent upstanding portion of the lever |98.

The outer or rear end of the lever 20| is provided with a depending cam roller 205 cooperating with a track 208 formed on a cam 201 which is secured to the drive shaft I9. 'I'he inner or forward end of the lever 20| is connected by a tension spring 208 to a fixed anchorage, which in this instance is a bracket on the frame member |16. Thus, the spring 208 serves to maintain the roller 205 against the track 208 of the cam 201 and provides the force necessary to move the bar |94 from right to left when this action is permitted by the contour and position of the cam track 208. Thus, the bar |94 is reciprocated in response to the cam 201, but the movement in both directions is made resilient, that from left to right being cushioned by the spring 204 and that from right to left being in response to the tension of the spring 208. Furthermore, inasmuch as the shaft I9 makes a single revolution during the mechanical cycle of the apparatus, the bar |94 will make a single complete reciprocation during` this same period to index the roll |84 a predetermined distance during each mechanical cycle of the machine. It will be understood that the cam track 208 is of such shape and so positioned on the shaft I9 as to impart the desired movement to the ribbon 52 through the apparatus.

Material drive- Pushing and locating means- Units 45, 46 and 47, Figs. 1, 2, 5 and. 6

While the rolls |84 and |81 of the unit 44 serve to draw the material through the heating and forming units, it is desired that certain ,of the subsequent units, particularly the perforating unit 48. the cotton unit 50 and the cut out unit 5| be provided with means for moving the ribbon 52 in a substantially positive manner to these units and locating the formed portions of the ribbon accurately in respect thereto. Inasmuch as these material actuating units 45, 48 and 41 are all substantially alike in construction, with the exception of the lengths of the fingers, as hereinafter set forth, but one will be described, the same reference characters being used on similar parts of all units.

Each of these units comprises one or, more pusher fingers 209, two being employed in the present instance, as there are two laterally spaced deprsions in each row. Each of the pusher fingers 209 is pivoted on a transverse axis 2|0 to a short bracket which in turn is secured to a bracket 2|| extending laterally from and secured to the longitudinally reciprocating bar |94. Thus as the bar |94 reciprocates from left to right, the right hand ends of the pusher fingers 209 will be moved by gravity to engage in ,the adjacent depressions, dueto their right-hand ends, Figs. 5 and 6, overbalancing their left-hand ends, and will move the strip or ribbon 52 forwardly the distance between two adjacent depressions, this being the distance the bar |94 reciprocates subsequent to the engagement of the right-hand ends of the fingers 209 in adjacent depressions.

Means are provided for determining the limits of movement of the fingers 209. For this purpose, the bracket 2| is provided with a forwardly extending bracket 2|2 through which extend adjustable screws 213 having lock nuts thereon for securing the adjustments once made. Similar screws 2|4 having lock nuts 2|5 thereon coopers'trip 52 as previously set forth. The reciprocation of the bar |94 in the manner heretofore explained will serve Ito move :the strip 52 forwardly a predetermined distance during each machine cycle and to locate the depressions therein accurately in respect to the operating units 48, 50 and 5| with which the respective moving units 45, 45 and 41 are associated.

Perforating unit 48, Figs. 1, v2, 5 and .11

The next operation to take place on the formed depressions in the strip 52'is to perforate the bottoms thereof so as-to provide a through passage for -a person to breathe when using the nas'al inhalers, to the vmanufacture of which the present machine is adapted. l

In order that the'perforation lof the depressions be accurate, means are provided for guiding the ribbon 52.111 a predetermined path opposite this unit. For this purpose, the ribbon 52 is guided by slide plates 2|1 having longitudinal slots therein for accommodating the downwardly extending flanges .at the edge portionsv of the strip, these plates being securedfto a laterally extending bracket 2|8 secured to a longitudinally extending stationary bar'2l9. The bar 2|9 is rigidly secured -to the brackets |95 and l96 in which the bar |94 is arranged for longitudinal reciprocation, these bars being disposed one above another as best seen in Figs. 11, 12, 13 and 14. Above the plates 2|1 are disposed spring plates 220, which overlie the lateral edge portions of the ribbon 52 and are urged resiliently downwardly by compression springs 22| surroundingbolts 222 which are secured in the plate 2|1 or the bracket 2|8, or both, `and which extend loosely through the plates 220, the springs 22| being confined between heads of .the bolts 222 and the upper surfaces of the plates 220. The underside of the bracket 2|8 is suitably cut out to provide for clearance of the associated parts ofthe depressed portions cf the ribbon 52 and the operating mechanism of the machine, as seen in the drawings.

The perforation of the depressed portions of the ribbon 52 is effectedfby upper die means 223 which have perforations .therein and with which cooperate punches 224 disposed below` the path of the ribbon and in alignment with theperforations of the dies 223. These parts are brought together so that the dies 223 enter into the depressions in the ribbon and center them while serving as a means against which the ribbon may rest during the perforation thereof by the punch members 224. The die members 223 are interchangeably carried by a supporting member 225,

. which is in turn secured to the lower end of an A vzo upper slide 226 arranged for vertical reciproca-v tion in guideways 221 formed in a frame member 228 which is secured to the rails I5 and l5 in any suitable `manner, as by vbolts 229. The punches 224 are interchangeably secured `to .a suitable ymounting means 230, carried Vby the upper end of a'lower slide 23|1which is mounted for vertical reciprocation in guideways 232 formed in the lower portion of the frame member 228.

Means are provided for reciprocating the upper and lower slides 226 and 23|; For this purpose,

these slides are respectively provided with cam rollers 233 and 234 which work in closed can-l suitably journaled in bearings formed in the frame 228 and having at their rear ends sprocket wheels 24| and 242 respectively. Around these sprockets ls .trained a sprocket chain 243, this chain also passing around an intermediate idler 244 carried by a bracket 245 from the rail I6 and around a driving sprocket 246 mounted jfor free rotation about the aids of the shaft |9.

As best seen in Fig. 2, the sprocket wheel 248 is carried by-one member 241 of a single tooth Itype of clutch, the other member 248 of which is provided with an annular groove to receive inwardly directed rolls 249, Fig. 11, mounted on lthe bifurcated ends 250 of a clutch lever 25| which is Divoted at 252 to a bracket extending downwardly from the rail IB and has a handle 253 at its forward end. A suitable bracket housingy 254 is provided having a slot in which the lever 25| moves and provided with suitable detents (not shown) for holding this lever at the oppositeA ends of its throwr against accidental dislodgment so as to hold the clutch, including members 2111v and 248 in or out. The arrangement is ,thus similar to that previously described for the shaping unit A43 as the sprocket Wheels 248, 24| and 242 are of the same diameter, so

that the cam plates 231 and 238 make a single revolution for each revolution of the drive shaft I9 and thus for each machine cycle. Furthermore, as .the clutch members 241 and 248 have but a single point of engagement, the perforating unit, when operating, must always be synchronized with the remainder of the apparatus.

As previously stated, Ithe die members 223 are provided with perforations therein so that the bits which are punched out from the-ribbon will be moved upwardly through these perforations into a hollow space 255 formed in the member 225 and in the head of the slide 226 and vthence Will pass through a chute 256 carried by the head of the slide 226 or the member 225 to be discharged into a stationary chute 251 to a point Where they will not interfere with the production of articles by the machine.V They may be directed thence to a desired collecting point in a y preferred way (not shown).

.adhesive lapplying amt 49, Figs. 1, 2, 6, 12 and 15 the longitudinal bar 2|9 has connected thereto a laterally disposed bracket 258, Fig. 12, which has thereon plates 259 having longitudinal slots formed therein to receive the downwardly extending anges of the ribbon 52. Above the plates 259 are plates 260 adapted to engage and guide the upper surface of the ribbon at its lateral edges. This construction differs, however, from that described for the perforating unit in that the members 260'and 259 are securely bolted together; and one or both ofthese members of eachrpair are recessed to a suicient extent to 

